Work Procedure for

Handling of Welding
Consumable
Effective Date:
January 19th 2013

Procedure No.:
EWP237

Revision: 01

Issue No.: 00

1.0 Scope
This procedure covers the requirements for receiving, handling, storage, drying, issuance/
return and identification of welding consumable material for use in fabrication of dished
heads.

2.0 Purpose
2.1

To ensure incoming Welding consumable Materials are inspected in

accordance with requirements of purchase order, and related code /
standards/referenced sections.

2.2

To ensure that handling, storage and drying of welding consumable

materials are in accordance with consumable manufacturers
recommendation.

2.3

To ensure of that non conforming welding consumable materials are

identified and separated out from usable welding consumable materials

3.0 Responsibility
Foremen- Assembly Group
4.0 References

ASME Section IX
Section II Part C- Specifications for welding rods, Electrodes and filler metals.
Material Management Procedure ECP001
Welding Control procedure ECP003
AWS - American Welding Society
Recommendations from Welding Consumable Material Manufacturers

5.0 Procedure
5.1

Control at receiving & storage areas:

5.1.1

Welding material will be kept in an identified location and shall be immediately checked for
shipping damage and determination of identity, quantity and compliance with the purchase
order requirements.

5.1.2

Incoming Inspection will be performed by QC Inspector (IMI) by Providing an IMI Number as

per Exhibit 4-8. Welding consumables if acceptable are released for storage with Sticker.

5.1.3

To assure that the received welding consumables comply with the requirements of the
purchase order the following shall be performed at the time of receipt;
a.
Consumable certificates shall be checked for the requirements specified in the
applicable specification and / or standard ( If requested in PO).

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Work Procedure for

Handling of Welding
Consumable
Effective Date:
January 19th 2013
b.

Procedure No.:
EWP237

Revision: 01

Issue No.: 00

Consumable certificates shall be verified against heat and / or lot or batch

numbers.

c.
5.1.4

5.2

Marking on the packages shall be reviewed for compliance with specifications .

All coated electrodes shall be stored in their sealed containers and shall not be left exposed to
the atmosphere. All welding consumables shall be stored in accordance with the
manufacturers recommendations.

Welding Material Distribution:

5.2.1

Issue
Foreman Assembly Group collects the welding consumables from stores using material
issue slip (Exhibit 7-7). Record of welding consumables issued order wise shall be
maintained by the Foreman (AG)
The QC Department shall have access to the records at all times and also to the
welding materials storage areas.

5.2.2

Shop Storage
Foreman Assembly Group shall load the Electrodes and Flux in ovens as specified in
the consumable handling instructions PARA 5-3. Ovens shall contain electrodes
placed in separated trays per AWS Specification,Brand and size. Foreman Assembly
Group is responsible for affixing proper tags showing batch no., type and size of
electrodes in correspondence of the trays. (Illustration A & B).
Covered electrodes and fluxes for submerged arc welding must be properly stored
and dried as per Consumable manufacturers recommendation. In case, Consumable
manufacturers recommendation is not available, then requirements of standard or
table -1 of this procedure will be followed. After drying, electrodes & fluxes shall be
kept at a holding temperature recommended by manufacturer. If recommendations are
not available it shall be held at a temperature as shown in table 1. Portable ovens or
quivers shall be used on the shop floor by welder to keep the electrodes at required
temperature.

5.2.3

5.2.3.1

Shop Distribution
Foreman Assembly Group shall remove the proper electrodes from holding oven and
distribute the electrodes to the welders.
No welder shall be issued with more than that can be used in a four hours period.

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Work Procedure for

Handling of Welding
Consumable
Effective Date:
January 19th 2013

Procedure No.:
EWP237

Revision: 01

Issue No.: 00

5.2.3.2

Foreman Assembly Group shall ensure that the welders receive the electrodes issued to
them in the heated Quivers available at their work station.

5.2.3.3

Upon issuance of electrodes and flux to welders, Foreman Assembly Group shall maintain
an issue register indicating date of issue, order no, batch no., weight, type, size and welders
name or ID.

5.2.4

Welding Material Return

5.2.4.1

All electrodes that are in good condition are returned to the Foreman Assembly Group and
stored in the holding oven. Record of issue register is updated upon return of welding
material.

5.2.4.2

Damaged, wet & unidentified electrodes shall be scrapped. All scrapped electrodes shall be
removed from the work area.

5.2.4.3

All low hydrogen electrodes that were exposed to atmosphere are returned and shall be redried in accordance with the electrodes manufacturers recommendations in the drying oven.
Returned and re-dried electrodes are stored in a separate tray and issued first so that these
are consumed. Electrodes are not dried more than twice.

5.2.4.4

All submerged arc flux shall be returned to the Foreman Assembly Group screened and
stored separately. This flux is mixed with new flux in the ratio of 1:2, dried and re-issued.

5.2.4.5

The container shall have the type of flux marked on it. At no time shall different types of flux
be mixed. Issue register is updated for returned flux.

5.3

Consumable Handling.

5.3.1

The Foreman Assembly Group checks electrode/Flux ovens and withdraw the quantity
required for the shift from the stores.

5.3.2

Forman Assembly Group shall load the Electrode/Flux ovens with quantity of low Hydrogen
Electrodes required as follows:
A)

Prior to use all low hydrogen electrodes shall be dried at temperature and
time recommended by the manufacturer in the drying oven. This drying is
be waived if the electrode is removed from hermetically sealed container.
Such electrodes can be used within 8 to 12 hours from the time of opening
the sealing.

B)

After drying the Foreman Assembly Group will transfer these electrodes in
the holding oven. The temperature of the holding oven will be at 700C- 1400
C or as per the manufacturers recommendation.

C)

The Foreman Assembly Group shall issue electrodes to the welder only
from the holding oven.

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Work Procedure for

Handling of Welding
Consumable
Effective Date:
January 19th 2013

5.4

Procedure No.:
EWP237

Revision: 01

Issue No.: 00

D)

The Foreman Assembly Group at the end of the shift will ensure that every
welder returns back all excess electrodes.

E)

Foreman Assembly Group must ensure that Electrodes inside the oven has
a proper identification.

SUBMERGE ARC FLUXES

5.4.1

All fluxes shall be stored in dry environment.

5.4.2

Any flux that has become wet shall be discarded.

5.4.3

Foreman Assembly Group shall ensure that there is enough flux in the oven.

5.5

SAW, GTAW, FCAW FILLER WIRES

5.5.1

All filler wires shall be stores in dry environment.

5.5.2

Any filler wire that has become visibly rusted or deteriorated shall be discarded.

5.5.3

Foreman Assembly Group shall draw quantity of filler wire from store sufficient for one shift
operation.

Table 1

TYPICAL STORAGE AND DRYING CONDITIONS FOR COVERED

ARC WELDING ELECTRODES
AWS
CLASSIFICATION
E7018,E78018-1 ,
E8018 & E9018
Non ferrous &
Stainless steel
Fluxes

STORAGE CONDITIONS
Ambient Air
Holding Ovens
Allowed
700 C 0
140 C after drying
Allowed
800C 1200 C after
drying
Un opened at 20 +/10 deg C
Recommended Max
Relative Humidity
60%

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1250C- 1750 C after

drying

DRYING CONDITION
2600C to 4250 C
1 to 2 hours at temperature
1200C 1500C for one hour
3000 C for 2 hours

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Work Procedure for

Handling of Welding
Consumable
Effective Date:
January 19th 2013

Procedure No.:
EWP237

Revision: 01

Issue No.: 00

Illustration A (DRYING OVEN)

Column # 1
Rack # 1

Column # 2

Column # 3

SS 316 L ( 2.5mm dia.) SS 316 L ( 3.2mm dia.)

(ESAB)
(ESAB)

SS 316 L ( 4.0mm dia.)

(ESAB)

Rack # 2

E 7018 ( 2.5mm dia.)

(ESAB)

E 7018 ( 3.2mm dia.)

(ESAB)

E 7018 ( 4.0mm dia.)

(ESAB)

Rack # 3

E 7018 ( 2.5mm dia.)

(ESAB)

E 7018 ( 3.2mm dia.)

(ESAB)

All size Returned

Electrodes (ESAB)

Illustration B (HOLDING OVEN)

Rack # 1
Rack # 2
Rack # 3
Rack # 4
Rack # 5
Rack # 6
Rack # 7
Rack # 8
Rack # 9

Column # 1

Column #2

SS 316 L ( 2.5mm dia.)

(ESAB)
SS 316 L ( 3.2mm dia.)
(ESAB)
SS 316 L ( 4.0mm dia.)
(ESAB)
E7018 (2.5mm dia.)
(ESAB)
E7018 (2.5mm dia.)
(ESAB)
E7018 (3.2mm dia.)
(ESAB)
E7018 (3.2mm dia.)
(ESAB)
E7018 (4.0mm dia.)
(ESAB)
All size Returned
Electrodes (ESAB)

SS 316 L ( 2.5mm dia.)

(ESAB)
SS 316 L ( 3.2mm dia.)
(ESAB)
SS 316 L ( 4.0mm dia.)
(ESAB)
E7018 (2.5mm dia.)
(ESAB)
E7018 (2.5mm dia.)
(ESAB)
E7018 (3.2mm dia.)
(ESAB)
E7018 (3.2mm dia.)
(ESAB)
E7018 (4.0mm dia.)
(ESAB)
All size Returned
Electrodes (ESAB)

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